Pavement method and composition with reduced asphalt roofing waste

ABSTRACT

A method of manufacturing and applying a novel pavement and patch material for roadways, driveways, walkways, patch for potholes and like surfaces, including the steps of reducing recycled asphalt roof waste to granules, adding aggregate and other solid recyclable materials to the granules, adding rejuvenating oil, adding emulsifier, adding asphalt concrete oil, adding anti-strip additives, adding liquid silicone, mixing the composition, heating the composition, applying the composition to the roadway or the like and compacting a new paving material.

This application is a continuation under 37 CFR 1.53(b) of applicationSer. No. 09/072,190, filed May 4, 1998, now U.S. Pat. No. 6,186,700,which is a continuation under 37 CFR 1.53(b) of abandoned applicationSer. No. 08/341,689, filed Nov. 17, 1994 now abandoned.

BACKGROUND OF THE INVENTION

This invention generally relates to the recycling and use of roofingwaste, including shingles, tar paper and portions thereof, and morespecifically to composition, method and use of reduced roofing wastematerials as a patch for potholes and a paving for roads, driveways,walkways and the like.

Methods and apparati for manufacturing asphalt paving compositions forroadways and the like are well known. Virgin aggregate is utilized,which is largely comprised of crushed rock, small rock, and sandgenerally one inch in diameter and down to a sieve size of 200. Threequarter inch in diameter is often preferable. Typically, virginaggregate is heated between 220° to 350° F. and dried in a rotatingdrum. Asphalt or asphalt-concrete oil is utilized with variouspenetration numbers ranging from 85 to 150, and which is also heated toa range of 280° to 350° F. The heated aggregate is then mixed withliquid asphalt in a proportion typically of five to six percent asphaltby weight. The paving composition is then hauled with trucks to the jobsite and dumped into a paving vehicle. The paver lays the hot mix outlevel to a desired thickness on top of a graded gravel surface of asuitable evaluation and smoothness. Thereafter the new pavement iscompacted with a roller to the desired density.

Commercial asphalt paving composition plants have a variety of problems.Asphalt plants are complex in that they require scales, tumble dryers,conveyors, furnaces, mixers, huge tanks for heating oil and asphalt oiland complex pollution control systems for controlling dust andemissions. Consequently, asphalt plants are stationary and not easilymovable.

Roofing materials, including shingles, tar paper and portions thereof,also utilize asphalt. The asphalt is commonly an asphalt-concrete oil(AC Oil) which is heavy and tar-like. FIG. 1 schematically shows incross section the composition of shingles 10. Shingles 10 begin with amat 12 which may either be fiberglass or of a paper felt-like material.Initially the mat 12 is soaked with a light saturine oil 14. Thereafter,a layer of asphalt-concrete oil 16 is applied thereto. Next a layer oflime dust 18 is placed or dusted thereon. Another layer of AC Oil 20 isapplied afterwhich a rock layer 22 is applied. Thereafter, the entirecomposition is run through rollers.

Considerable roof waste (RARW—Recycled Asphalt Roofing Waste) isassociated with the manufacture of new shingles, which may approximateone hundred million squares annually. A square is one hundred squarefeet of shingles. Each shingle has three tabs cut out. Each cutout tabmeasures one-quarter inch by five inches. The three discarded tabsrepresent approximately two and a half percent of each new shingle whichis discarded. When old shingles and tar paper are removed from oldconstruction, the one to three layers of shingles are all consideredwaste and are to be disposed of. Thus old shingle materials, also RARW,represent an even larger amount of waste associated with shinglematerials.

Methods and apparati have been disclosed by which old shingles andshingle material have been attempted to be recycled, such as those shownin U.S. Pat. Nos. 4,222,851; 4,706,893; 4,726,846; 5,201,472; 5,217,530;and 5,236,497. Illustratively, the '893 patent shows a method andapparatus wherein recycled shingles may be used in an asphalt plantmixed with heated and dried aggregate and liquid asphalt to form anasphalt paving composition. However, these prior methods of creatingpavements and apparati have not been commercially successful for variousreasons and especially due to their inability to create an acceptablepavement composition and to handle shingles without clogging or pluggingup apparati.

More specifically, shingle materials by their very nature pose a complexproblem in their reduction for recycling. The shingle materials,including the rock and asphalt oil in a range of twenty to thirtypercent, are extremely heavy, sticky and abrasive. Efforts to reduce theshingle materials to particles and granules in hammermills have met withthe clogging, plugging and sticking of the particles and granules withinthe hammermill, shutting down the production and necessitatingmaintenance and cleaning. Consequently, no one has reduced shinglematerials to a small enough size that will permit their use alone orwithin an asphalt plant.

Prior art pavements utilizing RARW or Recycled Asphalt Roofing Waste areplagued with the two basic problems of air voids and stabilization. Airvoids generally may be thought of as air pockets in the pavement. Theair pockets must not be too tight or there will not be enough room toallow the pavement to move or slightly expand during freezing. If theair voids or air pockets are too loose, the pavement will be highlysusceptible to water. Applicant has found that air voids in the range oftwo to eight percent are ideal and the prior art mixtures have hadproblems in attaining this acceptable range.

With respect to stabilization or firmness of the pavement material, thepavement material must not be too firm or it will not be workable inapplication as a pavement. Conversely, the material must have somedegree of firmness or it will not set up for traffic use and will resultin rutting. Applicant has found that a stabilimeter value of 800 to 3000is acceptable and the prior art pavement mixtures and materials have haddifficulty in consistently reaching this range.

The reason for the prior art mixtures and pavement materials' failure tomeet acceptable ranges of air void and stabilization values is largelydue to the many variables in making an acceptable paving compositionwith recycled roofing waste. The aggregate utilized is of a range ofsize from one inch to two hundred sieve size. The aggregate's porositymay also vary greatly. Furthermore, the aggregate may carry water for asignificant amount of moisture into the mixture which causes problems.The condition of the RARW or shingle materials greatly affects themixture. Older shingle materials commonly are oxidized and may have asignificantly reduced AC oil content. Also, shingle materials may carrymoisture, which also poses the problem described above. Some of theseproblems may be solved by conceivably superheating the mixture. However,equipment for superheating the mixture to a high enough temperature isnot available at this time.

There is a need for a method of manufacturing and applying a newpavement and patch composition material for roadways, driveways,walkways, patches for potholes and cracks and the like wherein thecomposition may include recycled roofing waste (RARW), aggregate,rejuvenating oil, recycled asphalt pavement (RAP), RARW and RAP(RAM—Recycled Asphalt Mixture), and other reduced solid materials,emulsifiers, liquid silicone and anti-strip additives that haveacceptable air voids and stabilization values without the need for acomplex and polluting asphalt plant.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art composition schematic of shingle materials;

FIG. 2 is a front elevational view of a huge pile of waste and discardedshingle materials, tar paper and portions thereof;

FIG. 3 is a perspective view of a front end loader utilized in graspingand conveying the waste and discarded shingle materials;

FIG. 4 is a front elevational view of a material reduction apparatus orshredder with oscillating cutter bars utilized in reducing the shinglematerials to pieces afterwhich the pieces fall upon a moving conveyor;

FIG. 5 is a top plan view of the shredder of FIG. 4 showing theoscillating cutter bars;

FIG. 6 is a side elevational view with schematics for the shinglereducing apparatus of the present invention;

FIG. 6A is a perspective view of the mill chamber of the hammermill withthe housing in phantom outline;

FIG. 6B is a cross-sectional view of the hammermill taken along lines6B—6B of FIG. 6A;

FIG. 7 is a front elevational view of reduced shingle materials packagedin a zip-lock type plastic bag;

FIG. 8 is a front elevational plan view of a method and apparatus forheating the reduced shingle granules;

FIG. 9 is a front elevational plan view of an alternative method andapparatus for heating the reduced shingle granules;

FIG. 10 is a cross sectional view taken along lines 10—10 of FIG. 9;

FIG. 11 is a front elevational plan view partially broken away of yetanother alternative method and apparatus for softening the shinglegranules;

FIG. 12 is a side elevational view of the invention in combination witha paver; and

FIG. 13 is a side elevational view of the present invention mounted ontrailers.

SUMMARY OF THE INVENTION

A method of manufacturing and applying a novel pavement and patchmaterial for roadways, driveways, walkways, patch for potholes and likesurfaces, including the steps of reducing recycled asphalt roof waste togranules, adding aggregate and other solid recyclable materials to thegranules, adding rejuvenating oil, adding emulsifier, adding asphaltconcrete oil, adding anti-strip additives, adding liquid silicone,mixing the composition, heating the composition, applying thecomposition to the roadway or the like and compacting a new pavingmaterial.

A principal object and advantage of the present invention is that itprovides a method, apparatus and use for reduced shingle materials downto the granular level as heretofore not known for use as patching ofcracks or potholes or paving for roadways, walkways, driveways and thelike.

Another principal object and advantage is that the reduced shinglematerial pavement or patch material of the present invention may beheated and used as surfacing for roads as well as jogging, walking andrunning trails and tracks and as a patch without the need of additionalasphalt or oil and may be used immediately after creation.

Another object and advantage is that rejuvenator oil may be added to thereduced shingle material for softening without heat for use as a pavingmaterial.

Another object and advantage of the present invention is that it permitsthe further combination of other recycled granular materials such ascrushed and pulverized glass, recycled asphalt pavement (RAP), RAM (RARWand RAP), crushed and broken concrete, or shredded plastic tires, to beadded thereto for use in creating a patch material or road pavingmaterial without the necessity of additional oils alone or combined in aconventional asphalt plant.

Another object and advantage of the present method is that it issignificantly simpler than complex asphalt plants without the need forcomplex scales, tumble dryers, conveyors, furnaces, mixers, huge tanksfor oils for both heating and asphalt oil and complex pollution controlsystems. The present apparatus is substantially pollution free andreadily transportable.

Another object and advantage of the present invention is that thegranular shingle material, when used as paving or patchwork, is lesssusceptible to frost or icing caused by the insulation qualities of thefibers of the shingles, making the surface safer for vehicle and humanuse in cold conditions.

Another object and advantage is that the present invention creates roadsurfacing materials for patching of potholes and paving of roadways fromreadily available shingles without the need for additional oils which isextremely cheap and which completely recycles existing waste materialswithout pollution.

Another object and advantage of the present method and pavement andpatch composition is that it is of a significant acceptable air voidpercentage of two to eight percent with an acceptable stabilizationstabilimeter value of eight hundred to three thousand.

Another object and advantage of the present invention is that theemulsifier additive assists in mixing the composition when there iswater or a moisture content either in the recycled asphalt roofing wasteor aggregate.

Another object and advantage of the present invention is that the liquidsilicone additive assists the pavement and patch composition in pavingas it smoothly comes out of the machine and assists in flowage of thecomposition.

Another object and advantage of the present invention is that theanti-strip additive assists in the coating of the aggregate.

Another object and advantage of the present invention is that both olderand newer recycled asphalt roofing waste may be utilized in the methodand composition.

Other objects and advantages will become apparent upon reading thefollowing specification, claims and reviewing the appended drawings.

DETAILED SPECIFICATION

Referring to FIGS. 2 through 6B, the apparatus and method used forreducing shingle materials without the need of additional asphalt or thecomplexities of an asphalt plant may be seen. The discarded and roofingwaste or shingles 24 heaped high in mountainous piles are loaded with afront end loader 26 into a material reduction apparatus 28 to createreduced shingle pieces 32. The shingle pieces 32 are then fed into theapparatus 36 comprising a first hammermill 38 and a second hammermill130 together with the associated plumbing. The shredded shingle pieces32 are reduced to shingle particles 120 and further into roofing wastegranules 136.

FIGS. 7 through 11 show methods and apparati 146 for heating the reducedshingle granules 136 for use as a repair material or patch for potholesor as a paving for roadways. FIG. 12 shows a wheeled vehicle 212 adaptedfor carrying the reduced shingle granules 136, heating the granules andevenly applying the heated granules 136 to the road surface 228afterwhich the new pavement may be compacted with a conventional roller240. FIG. 13 shows the invention being mounted on transportable trailers244.

Referring to FIGS. 4 and 5, the material reduction apparatus 28 may beseen. The apparatus 28 may also be referred to as a shredder withoscillating cutter bars 30 supporting knives. This shredding apparatus28 is disclosed in allowed patent application Ser. No. 07/967,159 filedon Oct. 27, 1992 in the name of Applicant's brother, Lawrence F. Omannand issued under U.S. Pat. No. 5,340,038 on Aug. 23, 1994. The materialreduction or shredding apparatus 28 reduces the large pieces and rollsof discarded and waste shingles 10 which have become compacted and stucktogether as they lay within the huge shingle pile 24. The apparatus 28reduces the shingles to pieces of a size on average of two to eightinches. As the shingle pieces 32 fall through the shredder 28, they landon a conveyor 34 which carries the shingle pieces 32 to the apparatus 36which reduces the shingle pieces 32 to particles 120 and later togranules 136. It is also known that material grinders work well formaterial reduction as shown in U.S. Pat. No. 5,344,088 issued on Sep. 6,1994 and marketed by Rexworks, Inc. of Milwaukee, Wis.

Referring to FIGS. 6, 6A and 6B, conveyor 34 leads to the firsthammermill 38 which includes an upper housing 40 having a shingle flowinlet 42 for receiving the shingle pieces 32. Within the housing 40 islocated a mill chamber 44 which has a ceiling 46 and an inner wall orwalls 48. Optionally, a flexible fabric-like sheet 50 may be suspendedalong but spaced from the inner wall 48 as will be appreciated. Accessinto the mill chamber 44 is gained by the outward swinging of doors 52and 54. The upper housing 40 is situated on a base 56 whichappropriately supports a motor 58 which turns a shaft or rotor 60. Aplurality of discs 62 are secured on to the rotor 60. The discs 62 areappropriately interconnected about their periphery by hammer pins 64which support spaced apart reversible swinging hammers 66. About thediscs 62 and hammers 66 spaced inwardly from the inner wall 48 islocated a curved screen 68. The screen 68 in the first hammermill 38appropriately may have apertures therethrough in the range of three tofour inches illustratively.

A water source 70 is provided from which extends a water line 72carrying twenty to thirty pounds per square inch of water. Naturally,the water is not used in extreme cold conditions. The water line 72enters into the mill chamber 44 through upper housing 40 into a watermanifold 74 which branches. Upwardly, is located a flow inlet water line76 with nozzles or apertures 78 therein used for spraying the reducedshingle pieces 32 as they enter the first hammermill 38 to preventsticking and to reduce or eliminate dust pollution. Mill chamber waterlines 80 are generally located adjacent the ceiling 46 and inner walls48 as they generally oppose each other and are located below and betweenthe shingle flow inlet 42. The water lines 80 appropriately have nozzles82 as to spray the mill chamber 44, ceiling 46, inner walls 48 andfabric sheet 50 (when used) with water as to discourage and reduce thesticking of shingle materials which otherwise may clog or plug thehammermill 38.

A compressed air source 84 is provided for supplying eighty to onehundred twenty pounds per square inch on average of compressed air. Acompressed air line 86 extends from the source 84 to a first pulse valve88 located suitably between the air line 86 and the compressed airmanifold 94. The first pulse valve 88 may be of a diaphragm plug-typecontrolled by a solenoid. An electrical line 90 extends from valve 88and is directed to a control box 92 which controls the first pulse valve88 as to permit compressed air to intermittently enter the air manifold94 every ten to fifteen seconds. The compressed air manifoldappropriately may be approximately two inches and permits large volumesof compressed air to enter therein when the valve 88 is actuated. Themanifold 94 has apertures 96 therein approximating one-half inch indiameter and in the range of six to thirteen apertures 96 in themanifold 94.

A second pulse valve 98 is also in line with compressed air line 86 atsecond compressed air manifold 104 and is controlled by electrical line100 extending from control box 92. The second pulse valve 98 issimilarly controlled as the first pulse valve 88, but to be actuated inan alternating fashion as to permit compressed air into the secondcompressed air manifold 104, which also has apertures 106 therein. Theair manifolds 94 and 104 are substantially parallel to the rotor orshaft 60 and generally located adjacent the ceiling 46 and inner wall48, as to discharge intermittently large amounts of compressed air whichimpinges on the mill chamber 44 surfaces, including the ceiling 46,inner wall 48, screen 68 and other components thereof. Additionalmanifolds 94 (shown in phantom outline) may be used within the millchamber 44 and directed wherever the reduced shingle materials have atendency to stick, clog or build up. Compressed air may also be directedbetween the inner wall 48 and the fabric-like sheet 50 on an alternatingbasis as shown by arrows. By this arrangement, the intermittent blast ofcompressed air shakes and ripples the fabric-like sheet 50 as to knockoff any clinging or stuck reduced shingle materials which otherwise maycling to inner wall 48.

Below the mill chamber 44 is located a discharge chamber 108 whichreceives reduced shingle material particles 120 which have beenpulverized by hammers 66 and pushed through screen 68. The dischargechamber 108 receives the reduced shingle material or particles 120 thatare knocked off from the mill chamber ceiling 46, inner walls 48 andscreen 68 by way of the intermittent compressed air blasts aided by thewater. The discharge chamber 108 also suitably has a baffle 110 thereinwhich assists in keeping the dust at low levels in extreme temperatureswhen water cannot be added to the hammermill 38. An auger 112 issuitably located in the base of discharge chamber 108 and draws thereduced shingle materials in the form of particles 120 from thehammermill 38. An exhaust duct 114 is appropriately located behindbaffle 110 and appropriately has an in-line suction fan 116 in flowcommunication with a dust collector 118. The exhaust duct work 114 isappropriately actuated when water cannot be utilized as in cold weatherand it is necessary to collect the dust and soot created by thehammermill 38 to prohibit pollution.

Shingle particles 120 exiting the first hammermill 38 are generally onaverage in a range between one-eighth inch to four inches. The particles120 are drawn by auger 112 onto the second conveyor 122 which is thensuitably fed into a second hammermill 130 for reducing the shingleparticles 120 to granular shingle material 136 wherein sixty to eightypercent of the end product is powder and granules less than one-halfinch in diameter and averaging one-eighth inch but no more thanapproximately one inch. A gradation test of the granular shinglematerial 136 produced the following summary:

% of Shingle Sieve gradation Granules 136 Passing .375 100  .187 (#4) 74.0787 (#10) 72 .0331 (#20) 51 .0165 (#40) 40 .0070 (#80) 28 .0029 (#200)25

Optionally, a third conveyor 124 may lead from a storage bin 126 whichappropriately holds shredded recycled asphalt pavement (RAP) or plastictires, crushed glass, gravel, sand, crushed concrete or other shreddedor granulated material 128 for addition onto the second conveyor to bemixed with the shingle particles 120 in the second hammermill 130. Ithas been found that there is adequate oil content within the shingles 10as to permit the addition of these recyclable materials for use in patchor road paving.

The second hammermill 130 is essentially the same as the firsthammermill 38 with one exception. That is, the three to four inch screen68 is replaced in the second hammermill 130 with a screen 132 which hasapertures therein in a range on average between seven-sixteenths andthree-quarters of an inch. The exact aperture size of screens 68 and 132are directly dependant upon the ambient air temperature and the speed ofthe rotor 60, discs 62 and hammers 66 which are generally in a range oftwelve hundred to eighteen hundred r.p.m. Higher r.p.m.'s mean thescreens may be of a larger diameter while the hammermill has better wearat lower r.p.m.'s.

The reduced granular material 136 is placed upon a third conveyor 134from the second hammermill 130 and fed into a storage or surge bin 138which appropriately may have an auger 148 in its base leading to adischarge outlet 142. The shingle granules 136 may be bagged or packagedsuitably in ziplock like bags, paper bags or cardboard boxes as shown inFIG. 7 for home use in patching cracks or potholes in walkways,driveways and the like.

Testing has revealed that packaged granular shingle material 136 inplastic bags, paper bags with or without an inner layer or staininhibitor film (popcorn bags), more rigid plastic containers or the like144 will permit the consumer to heat relatively small amounts in a homemicrowave. For instance, three pounds of the granular material 136 maybe heated in a fifteen hundred watt microwave for four to six minutes upto a temperature on average of two hundred degrees. Thereafter thesticky and soft granular shingle material 136 may be applied to cracksor potholes. A three pound package will do approximately a six inchsquare of approximately one and one-half inch compacted thickness.

Referring to FIG. 8, the larger scale or commercial application ofheating the shingle granules 136 may be appreciated. Granules 136 aredischarged from outlet 142 of storage bin 138 onto a conveyor belt 148which passes through a microwave oven 150. Thereafter, the heatedshingle granules 136 may be dumped into a hot storage bin 152 for use ortransport to the location for use. Tests have revealed that a fifteenhundred watt microwave will heat approximately one pound of granules 136to 250° F. in one and a half minutes.

Referring to FIG. 9, an alternative heating means for the shinglegranules 136 is revealed. The granules 136 are again discharged fromstorage bin 138 into a tilted rotating cylindrical heater drum 154having an open front 156 and a material receiving trough 158. A burnersupplying hot air 160 is directed inwardly at the open front 156. Asseen in FIG. 10, fins 162 are located within the drum 154 which aid inthe tumbling and tossing of the shingle granules 136 during heating. Thedrum 154 has an open rear 164 and a dump shoot 166 for dumping theheated granules 136 into a hot storage bin 152. Again, an exhaust duct168 having an in-line fan 170 may be utilized to reduce and preventpollution to the ambient air or atmosphere by directing the exhaust todust collector or scrubber 118.

Referring to FIG. 11, another alternative embodiment of heating theshingle granules 136 may be appreciated. The granules 136 are dischargedfrom storage bin 138 onto a conveyor 182 above which is located a fuelsource 184 having nozzles 186 therein. Fuel 188, such as gasoline,kerosine or fuel oil, is discharged from nozzles 186 onto the granules136 and then dumped into a tilted, rotating cylindrical ignitor drum 190having an open front 192 and a receiving trough 194. An ignitor 196 witha pilot 198 extends through the open front 192 into the rotating ignitordrum for igniting the fuel 188 and heating the granules 136. Fins 200are also utilized in the ignitor drum 190 for mixing purposes. The drum190 has an open rear 202 with a dump shoot 204 leading into a hotstorage bin 152. The exhaust duct 168, fan 170 and collector scrubber118 arrangement may also be used with this arrangement. Tests haverevealed that five hundred pounds or one-quarter ton of granules wouldrequire approximately one gallon of fuel for this method of heating.

Referring to FIG. 12, a wheeled vehicle 212 may be seen which may beused as a paver for applying the heated granules 136. Vehicle 212appropriately has a granular shingle material storage bin 214 with anauger 216 in its base. Auger 216 draws the granules 136 onto inclinedconveyor 218 afterwhich the granules 136 optionally may be sprayed withfuel 220 depending on the appropriate heating means 222 as previouslydisclosed. The heated granules are then dumped into a trough 224 havingan auger 226 for spreading the granules 136 in heated condition evenlyupon roadway 228. Drag arms 230 extend backwards having a screed 232 attheir ends with cylinders 234 adjustable for adjusting the pressure ofscreed 232. The control of the paving on vehicle 212 may be handled at acontrol center 236. After application, a conventional roller 240 mayoptionally compact the new pavement afterwhich it may immediately bedriven upon or used by the public.

FIG. 13 illustrates the mounting of the shredder 28, first and secondhammermills 38 and 130 and storage bin 138 on trailers 244 fortransportation to the site for operation.

The shingle granules 136 may be softened for paving with the addition ofa rejuvenator oil, gasoline, mineral spirits, flux oil, mist oil, usedmotor, hydraulic or heat exchanger oil, kerosine or fuel oil and tumbledin a rotating drum 154 or 190. After paving, the new pavement should beunused for a while to permit curing and evaporation of the rejuvenatoroil.

Rejuvenating oil or the like has been found to be highly advantageous insoftening up the asphaltic bituminous within the recycled asphaltroofing waste (RARW) recycled asphalt pavement (RAP), and in recycledasphaltic mixture (RAM), which is a blend RARW and RAP. Variouspetroleum products may be used as a rejuvenating oil to include fueloil, kerosene, mineral spirits, gasoline, flux oil, mist oil, usedmotor, hydraulic or heat exchanger oil and the like. With the asphalticbituminous or AC oil softened and somewhat liquified, the asphaltic oilwill then more readily transfer to coat the aggregate.

As previously stated, aggregate can include sand and rock in the rangeof one inch down to a 200 sieve size with ¾ ″ being preferable. Theaggregate can also include recycled asphalt pavement (RAP), crushed andbroken concrete, crushed glass, as well as shredded tires and plastics.

Applicant has found that the moisture stored in the aggregate, recycledasphalt pavement and recycled asphalt roofing waste may be in the rangebut approximately near ten percent. What this means is that therejuvenating oil may be rejected by the aggregate and roofing waste andhave a tendency to bead off. Applicant has found that different types ofemulsifiers generally work well to permit the petroleum products toblend and loosen up to coat the aggregate while yet handle any moisturecontent. Emulsifiers may be made by alkaline hydrolysis of esters(naturally occurring fats and oils), sometimes referred to as soaps. Oneounce of emulsifier has been found to adequately treat one gallon ofwater or approximately eight pounds of moisture content. To increase theratio or amount of emulsifier does not in any means damage the finalpavement product.

The emulsifier is suitably premixed with the rejuvenating oil for easeof handling. An example for proportioning emulsifier RAP, RARW andrejuvenating oil is as follows:

EXAMPLE: 1 Ton Mixture

RAP 900 lb 45% at 10% moisture content RARW 900 lb 45% at 10% moisturecontent RAM 1800 lb  90% at 10% moisture content

Or RAM could equal 1620 lbs of RAM plus 1801 lbs moisture content toequal 1800 lbs RAM.

Emulsifier  1.4 lbs  .07% Rejuvenating oil 198.6 lbs 9.93%  2000 lbs 100%

Minimum requirement: 1 ounce emulsifier for 8 lbs moisture content.

180 lbs moisture content divided by 8 equals 22.5 ounces divided by 16(16 ounces equals one pound).

Dividing 22.5 ounces by 16 equals 1.4 pounds.

Rate RATIO RAP 0%-95% RARW 5%-95% Emulsifier .01%-.3%  Rejuvenating oil1%-10%

Making a hot mix by using RARW and RAP (RAM) by mixing a desired amountusing a microwave energy results in a 100% recycled hot mix. Range ofheat should be 120 degrees to 350 degrees Fahrenheit, enough to softenthe existing AC oil to create a binding effect when compacted. Forexample:

RATIO: RAP 1%-95% RARW 5%-99%

By having two sources of asphaltic roof waste (RARW and RAP), the methodsaves time in mixing after being heated. This is because we do not needto transfer any of the asphaltic bitume oil from one asphaltic productto the other. RARW has a content of asphaltic bitume of a range of 20%to 50%, and RAP has a content of asphaltic bitume of a range of 3% to8%. Also, RAP if processed down to a size of a courser aggregate (¼″ to¾″), will require less rejuvenating oil than if sized to a ¼″ minus.

Collection of asphaltic roof waste for processing usually has threedifferent types of asphaltic product. Some will be of the fiber glassasphaltic shingles, some will be of paper or felt asphaltic shingles andsome will be from flat roofs or commercial buildings being made up ofasphalt and rock. The proportioning with recycled asphalt roofing wastedepends on if the product is from commercial flat roofs or shingles. Themakeup of flat roofs is basically A.C. oil coated with a layer of rock,this would require a lesser amount of rejuvenating oil. If the productis organic or felt asphalt shingle material processed down to 1″ minusit would take more rejuvenating oil than if processed down to ¼″ minus.If the product is of a fiberglass shingle, again it is true the largerthe size the more rejuvenating oil it will take but overall the organicor paper felt shingles size being of the same size as the fiber glassthe fiberglass mixture will absorb or require less rejuvenating oil.

There may also be other miscellaneous debris when collecting asphalticroof waste such as small amounts of wood waste, paper, plastics, metal,etc. Metal can be pulled out through the process with magnets but inmost cases the rest of the debris can be processed down without any harmto the finished products. When processing RARW, the smaller the sizingthe better the results or utilization of this product.

When storing RARW for any period of time before using, the product tendsto stiffen or bond together, making it hard to handle, mix or blend to adesired application. By taking a selected amount of RAP, preferred sizeof ¾″ minus, and blending the RAP with the final sized RARW suitably byconveying the RARW and RAP together by means of belt scales or othermetering devices, the combination may be stockpiled. This will eliminatethe problem of the RARW bonding together. These stockpiles can beblended for different applications. Storage piles can be made up of ablend for different applications such as cold mix, cold patch, hotrecycle mix or a straight cold pavement application (straight coldpavement application is made without rejuvenating oil or solvents) inthe following ranges:

Range or proportioning 15%-90% for RAP. Range or proportioning 20%-90%for RARW.

By mixing RAP and RARW without rejuvenating oil or emulsifier, thisproduct in hot climates and low traffic areas can be used as a coldpavement. By grading this product directly onto graveled roadways,parking areas, walkways, etc., at a desire thickness and compacted withconventional rollers, the ambient temperatures and direct sunlight willsoften the asphalt oil in this product and create a bonding effect.

A liquid silicone or silicone emulsion will greatly assist in the newpavement mixture composition as it exits the pavement machine. Theslippery quality attributable to the silicone will assist in keeping theasphalt flowing. Similarly, an anti-strip additive will also help inallowing the aggregate to be coated and act as surfactants to improveadhesion.

By using RARW, gravel and rejuvenating oil and mixing at ambienttemperature, there remains a few problems. The amount of rejuvenatingoil it takes to soften or activate the asphalt oil and the RARW totransfer to the gravel to coat the rock or granular material is fairlyexcessive which causes curing time or tenderness delay because of theexcess rejuvenating oil. If too much rejuvenating oil is added, it willalso lose its stabilization, making it an unusable end product for roaduse or a very limited one. The moisture content of the RARW and thegravel when adding the rejuvenating oil tends to repel the rejuvenatingoil thus making it more difficult to transfer the asphaltic recycled oilfrom the RARW to coat the rock or granular material properly.

To correct the problem of getting the asphaltic oil in the RARW totransfer to the gravel with minimum rejuvenating oil would be to havethe gravel and the RARW heated, which would soften the asphaltic oil inthe RARW thus taking less rejuvenating oil to get the asphaltic oil totransfer to coat the gravel properly, and making it an instantly usableproduct for conventional means. Because of the lower amount ofrejuvenating oil used, the tender or the curing time is lessenedconsiderably to where it is very comparable to the standard hot mix. Tosolve any moisture problems in the composition, an emulsifier may haveto be added to the rejuvenating oil. As long as the mixture (gravel andRARW) is higher than 120°, the amount of rejuvenating oil can bedecreased than if it was mixed at ambient temperature. If the gravelmixture is heated together by conventional means or microwave energy,then the rejuvenating oil needs to be added to this process whilemixing. The use of different types of rejuvenating oil is critical fordifferent results of pavement mixture. For instance, the use of a lightfuel, such as kerosene or #1 fuel, will evaporate quicker and be lesstender, whereas a #5 heavy oil will stay tender longer (#1 fuel oil mustbe mixed at a lower mixing temperature than a #5 or heavier oil).

Problems exist when mixing both at ambient and heated temperatures. Whenmixing at ambient temperature, the given amount of rejuvenating oil ittakes to transfer asphalt from the RARW to aggregate is too excessive tomake a useable product for any road use because its stabilization is toolow and the amount of curing time is too long. The heated process withaggregate and RARW with conventional means also has problems intransferring asphalt to aggregate, because of the amount of RARW neededin the final product. The RARW extracts too many BTU's from the hotaggregate mainly because of the moisture problems. Conventional asphaltplants today are not designed to heat hot enough to handle this producteffectively without serious problems. If RARW was free of moisture andif asphalt plants could heat hot enough, there would still be problemswith air voids and workability with the product.

All these problems can be eliminated by a new method of combining thetwo previous methods mentioned by treating the rejuvenating oil withadditive such as emulsifier, silicone and anti-strip to create a uniformmix that meets air void and stabilization specifications, and has aworkability comparable to conventional hot mix at a lower temperature ofa range approximately 200°. This process can easily control air voidsand stabilization by adjusting coarseness of aggregate or the amount ofRARW or the amount of rejuvenating oil. Workability can be adjusted bythe temperature of mixture, amount of RARW and amount of rejuvenatingoil.

To treat the rejuvenating oil with silicone, calculate the percentage ofthe asphalt in the RARW to percentage used in RAM to percentage ofrejuvenating oil used. One pint treats approximately 24 ton of asphaltcontent in RARW.

When processing of roof waste, the blending of the pile beforeprocessing and after, take the average AC content found in the pileafter moisture content. If average AC is 20% out of 2000 lbs=400 lbsasphalt content. If too low it may need to increase the amount of RARW.If impossible to do so because of moisture or type of aggregate, thenthere may be a need to add virgin AC oil.

The present invention may be embodied in other specific forms withoutdeparting from the spirit of essential attributes thereof; therefore,the illustrated embodiment should be considered in all respects asillustrative and not restrictive, reference being made to the appendedclaims rather than to the foregoing description to indicate the scope ofthe invention.

What is claimed:
 1. A hot mix pavement and patch material for roadways,driveways, and walkways from roof waste, comprising a mixture of 95 to 5percent by weight recycled asphalt roof waste heated with 95 to 0.5percent by weight aggregate, further comprising 1 to 10 percent byweight rejuvenating oil, and 0.01 to 0.3 percent by weight emulsifier.2. The pavement and patch material of claim 1, further comprising lessthan six parts by weight non-emulsified asphalt concrete oil.
 3. Thepavement and patch material of claim 1, further comprising less than onepart by weight anti-strip agent.
 4. The pavement and patch material ofclaim 1, further comprising less than one part by weight liquidsilicone.
 5. The pavement and patch material of claim 1, wherein therejuvenating oil is selected from the group consisting of fuel oil,kerosene, mineral spirits, gasoline, flux oil, mist oil, used motor oil,hydraulic oil, and heat exchanger oil.
 6. A hot mix pavement and patchmaterial for roadways, driveways, walkways from roof waste, comprising amixture of 95 to 5 percent by weight recycled asphalt roof waste heatedwith 95 to 0.5 percent by weight aggregate, further comprising 1 to 10percent by weight liquid, flowing rejuvenating oil, and furthercomprising 0.01 to 0.3 percent by weight emulsifier, wherein therejuvenating oil is selected from the group consisting of fuel oil,kerosene, mineral spirits, gasoline, flux oil, mist oil, used motor oil,hydraulic oil, and heat exchanger oil.
 7. The pavement and patchmaterial of claim 6, further comprising less than one part by weightliquid silicone.
 8. The pavement and patch material of claim 6, furthercomprising less than six parts by weight non-emulsified asphalt concreteoil.
 9. The pavement and patch material of claim 6, further comprisingless than one part by weight anti-strip agent.